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Boiler Tune-up Guide

National Emission Standards for Hazardous Air Pollutants for Area Sources:Industrial, Commercial, and Institutional Boilers

40 CFR Part 63 Subpart JJJJJJ

What is a boiler tune-up?

A boiler tune-up refers to many aspects of improving boiler operations. Inthis Guide, the termboiler tune-up specifically refers to the activity to meetthe requirements in the Boiler Area Source Rule (40 CFR Part 63 SubpartJJJJJJ).

The tune-up activity is the act of reestablishing the air-fuel mixture for theoperating range of the boiler. Oxygen and unburned fuel (carbonmonoxide is generally the indicative measurement) are balanced toprovide safe and efficient combustion. Carbon monoxide (CO)concentrations are also measured to ensure proper burner operation.

A primary goal of a boiler tune-up is to improve boiler efficiency withrespect to combustion operations.

What are the tune-up requirements under the Boiler Area Source Rule?

See 63.11223(b) for the actual requirements.

See the Tune-up Guidance and Example Recording Form AreaSources posted at http://www.epa.gov/ttn/atw/boiler/boilerpg.html forinformation on compliance dates, recordkeeping, and reporting

requirements.

The purpose of this Guide is to provide the boiler owner the knowledgebase to appropriately direct boiler tune-up activit ies to comply wi th therequirements of the Boiler Area Source Rule. This w ill allow the boilerowner to clearly define the scope of work the tuning technician will betasked to accomplish.


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Who should perform the actual tune-up?

Al l boi ler adjustments and modif ications should be completed by qual if ied,experienced technic ians.

Boiler operations in general and tune-up activities in particular are

hazardous and require the skill and knowledge of experiencedtechnicians.

The tune-up technician should be skilled in the evaluation and adjustmentof the specific boiler and burner equipment in use.

What are the basic activities and minimum requirements associated wi th a boilertune-up?

The following is a simple checklist that highlights the basic activities andrequirements associated with a boiler tune-up to comply with the requirements of the

Boiler Area Source Rule. The checklist is intended to be a time ordered tool to aid inplanning and conducting boiler tune-ups.

1) Preparation

a) Clearly identify the target equipment along with the intent and goals of the tune-up.

b) Assemble boiler drawings and data sheets.

c) Assemble burner drawings and data sheets.

d) Assemble combustion control information.

e) Identify environmental regulations and limitations.

i) Typically nitrogen oxides (NOx) and combustible material (often identified asCO) are specifically addressed in the emission limits.

f) Identify steam production control strategy that will be used during the tune-up.

g) Identify in-situ instrumentation and verify calibration.

h) Identify measurement locations and verify access.

i) The most common flue gas measurement location is immediately

downstream of the steam generation section of a water-tube type boiler. For afire-tube type boiler the flue gas sample is most commonly taken as theexhaust gases exit the boiler proper.

i) Establish tune-up timeframe.


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2) As-found observation

NOTE: Identification of the as-found conditions centers on measurement of theoperating parameters of the combustion process that will be modified during the tune-upprocess. The primary measurements required under the Boiler Area Source Rule areflue gas oxygen content and flue gas carbon monoxide content at the high-fire or typical

operation load.

a) Examine the combustion control components (i.e., the system controlling the air-to-fuel ratio) and ensure it is functioning properly.

b) Examine the burner internal components and identify any defects, if applicable.

c) Examine the general boiler conditions and identify any defects.

d) Measure and record the following for each operating position of the combustioncontrol system.

i) Observe flame pattern, flame dimensions, and burner condition.

ii) Flue gas oxygen content.

iii) Flue gas carbon monoxide (CO) content.

iv) Flue gas emissions content (NOx, if appropriate).

(1) Additional flue gas component analysis is required when theenvironmental permit specifies limits on emission components. A commonregulated emission component is nitrogen oxides (NOx).

v) Emissions control settings.

(1) Flue Gas Recirculation flow settings (if applicable).

vi) Final flue gas temperature.

e) Document any modifications completed at this point.

3) Tune-up

The tune-up activity is the act of ensuring the burners are properly mixing the air andfuel and of reestablishing the most appropriate amount of excess air throughout theoperating range of the boiler.

a) Tune-up each operating position of the combustion control system (from high-firethrough low-fire).

NOTE: The ru le [63.11223(b)(4)] only requires that the tune-up beconducted at high-fire or the typical operating load.

i) Establish steady operation for the target operating point.


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ii) Adjust combustion control position relationship to achieve desired combustioncharacteristics.

(1) Flue gas oxygen content - target will generally be the manufacturersspecifications.

(2) CO content - target will generally be the manufacturers specifications.

(3) NOx content, if applicable target will generally be the limit specified inthe environmental permit.

(a) Adjustments for emissions control are generally completed aftercombustion adjustments are established.

iii) Measure and record the following for each operating position of thecombustion control system.

NOTE: Only the high-fire or typical operating load need to be recorded tocomply with the rule [63.11223(b)(6)].

(1) Observe flame pattern, flame dimensions, and burner condition.

(2) Flue gas oxygen content.

(3) Flue gas CO content.

(4) Flue gas emissions content (NOx and others).

(5) Final flue gas temperature.

iv) Document any modifications completed at each point.

4) Document tune-up.

a) Document the tune-up including the following.

i) As-found conditions.

ii) Post tune-up conditions.

iii) Modifications and repairs completed.

iv) Recommended investigations and modifications.

v) Identified shortcomings of the equipment.


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What tools or methods can be used to measure oxygen and CO?

The primary tool required to complete a boiler combustion tune-up is a flue gasanalyzer. The required measurements for an appropriate flue gas analysis are flue gasoxygen content, combustibles content, and any components that are managed as a part

of environmental compliance (NOx for example). These measurements are typicallyobtained with a portable combustion analyzer.

NOTE: This Guide is in no way intended to advise a departure fromthe boiler or burner manufacturers instructions andrecommendations.

What if I need more detailed information on performing a boiler tune-up?

For More Information: Boiler Tune-up Guide for Area Source BoilerOwners is based on the Boiler Tune-up Guide for Natural Gas and LightFuel Oil Operation, prepared by Greg Harrell, DOEs Energy ManagementServices which presents:

o A general discussion of boiler efficiency and the influencecombustion control has on efficiency.

o The basic combustion control methods.o The typical field activities associated with tuning a boiler.o The methods for evaluating the economic impact associated with

tuning a boiler.o A basic discussion of the environmental impacts that can be

expected with a boiler tune-up activity.o General reference data that can be useful in boiler tune-up

evaluationso A list of general references that may prove useful in tune-up

activities. This Guidebook can be found at:

http://www.epa.gov/ttn/atw/boiler/boilerpg.html

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